Stress-bearing assembly

Abstract

A stress-bearing assembly is for use in a vehicle body. The assembly includes a composite laminate resin-cured structure comprising at least a pair of oriented fiber mats separated by a layer of foamed plastic and at least one closed loop structure attached to the composite structure. The mats preferably comprise glass fibers, carbon fibers or fabric material, and the composite structure preferably constitutes the floor structure of a vehicle.

I claim: 
     
       1. A stress-bearing assembly for use in a vehicle body, said assembly comprising a composite laminate resin-cured structure comprising at least one pair of fiber mats separated by a layer of foamed plastic, and at least one closed loop structure attached to said composite structure, said closed loop structure comprising a generally inverted U-shaped hoop member and a transversely extending member closing said hoop member to form said closed loop structure. 
     
     
       2. The stress-bearing assembly as claimed in claim 1 wherein said at least one pair of fiber mats comprise material selected from the group consisting of glass fibers, carbon fibers, and fabric. 
     
     
       3. The stress-bearing assembly as claimed in claim 2 wherein said composite structure constitutes a floor structure of a vehicle. 
     
     
       4. The stress-bearing assembly as claimed in claim 3 wherein said at least one closed loop structure comprises at least two said closed loop structures comprising magnesium and serving as a portion of a vehicle passenger compartment. 
     
     
       5. The stress-bearing assembly as claimed in claim 4 further including a roof panel comprising a composite laminate resin-cured panel comprising at least one pair of oriented fiber mats separated by a layer of foamed plastic extending over and between said at least two closed loop structures. 
     
     
       6. The stress-bearing assembly as claimed in claim 4 or 5 further including a door structure comprising an inner frame comprising magnesium and an outer panel, said door structure forming a portion of said passenger compartment. 
     
     
       7. The stress-bearing assembly as claimed in claim 6 wherein said outer panel of said door structure comprises a composite comprising an inner layer of fiber-reinforced plastic and an outer layer of metal foil bonded to said inner layer. 
     
     
       8. The stress-bearing assembly as claimed in claim 7 wherein said outer layer of metal foil comprises a metal selected from the group consisting of steel and aluminum. 
     
     
       9. The stress-bearing assembly as claimed in claim 3 further including a body panel comprising a sheet of metal, and a liner of fiber reinforced plastic attached to said sheet of metal at at least one discrete point, said liner serving as both a strengthening element and a sound absorbing element. 
     
     
       10. The stress-bearing assembly as claimed in claim 3 further including a suspension assembly comprising a subframe and a generally omega-shaped composite spring and wheel location member. 
     
     
       11. The stress-bearing assembly as claimed in claim 10 wherein said spring and wheel location member is pivotably attached to said subframe at a pair of pivot locations, each of said pair of pivot locations being immediately adjacent to a front wheel. 
     
     
       12. The stress-bearing assembly as claimed in claim 11 wherein said spring and wheel location member is resiliently supported by said subframe at at least one location substantially equidistant from said pair of pivot locations. 
     
     
       13. The stress-bearing assembly as claimed in claim 3 or 12 further including a rear suspension assembly comprising a composite spring and wheel location member.